6th European Waste Water Management Conference & Exhibition

ZERO DISCHARGE OF WASTE WATER FROM JUICE MAKING INDUSTRY USING VERMIBIO-FILTRATION TECHNOLOGY
Ghatnekar, S.D., Ghalsala-Dighe, D.S. and Ghatnekar, S.S.,
Biotechnology Resource Centre, India
Email: brc_suvash@hotmail.com
The paper describes the novel vermi-bio-filtration technology developed by BRC to treat the
liquid effluents produced by Gujrat based juice making industry into bio-clean and bio-safe
water. The treated bio-clean water can be used to clean floors and vessels as well as for any
secondary purpose except for drinking.
Around 80-85 sq. m area is required to set-up this novel plant having capacity to treat 12,000
liters of effluents everyday. The multi-stage plant consists of four vermi-bio-filters. The principle
of trickling filter is used in the system. Each vermi-bio-filter is accompanied by a sump and upper
layer consists of sterilized bedding material inclusive of selected microorganisms, enzymes and
worms. This layer has to be replaced after 6-8 months and the resultant biomass with specific
pre-treatment could be used as pro-biotic nutrient for the crops. The COD of wastewater was
reduced from 12,000 ppm to less than 200 ppm. The total recurring cost to treat 12,000 liters
effluents everyday works out to be Rs. 50-60 ( 0.75-85) whereas, in the conventional ETP plant,
the running costs will be Rs. 5000-6000 ( 7.5-10). The capital cost of the plant is also 6-7 times
less than the conventional ETP plant.
In fine, the implementation of this innovative technology results not only into pollution
abatement but into zero discharge as well.

Keywords
Earthworms, enzymes, microorganisms, pollution abatement, vermi-bio-filter, wastewater, zero
discharge.

Introduction
In the recent past, developing countries like India have changed their approach towards the
treatment of liquid effluents. The research has been intensively directed towards simpler,
energy saving, environmentally bio-safe and cost-effective technological solutions. In addition,
the environmental regulations by Pollution Control Boards have undergone vast changes. As a
result, conventional treatment technologies have been further refined and new technologies
for wastewater treatment are being implemented and/or are in the development stage to meet
increasingly more stringent water quality criteria (Kumar et al. 2008). Today, most of the
wastewater treatment plants have started looking for biotechnological alternatives in their
systems. Apart from the benefits of improved capacity, efficiency and lowered operative costs,

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microorganisms, enzymes and earthworms also keep the treatment process as natural as
possible.
Amongst the varied biotechnological methods of wastewater treatment adopted, vermiculture
biotechnology and microbial wastewater treatments are gaining wide popularity. Earthworms
have proved to be master bio-processing agents for the management of organic effluents from
diverse sources ranging from domestic sewage to industrial refuse (Ghatnekar et al. 2000).
Startlingly, they convert effluents that are an undesirable nuisance into coveted plant probiotics
in the form of soil-conditioners. The use of microorganisms is also considered as an integral part
of the wastewater treatment process. Higher concentration of microorganisms is able to remove
the organic matter from the water at a faster rate, particularly in the case of lagoon systems
where it can take several months for the complete degradation process. In this context,
Biotechnology Resource Centre, India has developed a novel technology using multi-stage
vermi-bio-filters with the key objective of converting industrial liquid effluents into bio-safe and
bio-clean water.
Since last 30 years, Biotechnology Resource Centre, India has contributed towards uniting the
environment and economy by developing innovative, bio-safe waste treatment technologies
of global importance (Ghatnekar and Kavian 1992; Ghatnekar et al. 2009a). BRC has
successfully commissioned vermiculture-based effluent treatment plant (ETP) in diverse industrial
units (Ghatnekar et al. 1995; Kavian and Ghatnekar 1999). The developed three-tier
vermiculture biotechnology involves the synergistic action of selected enzymes,
microorganisms and earthworms for degradation of complex organic wastes in both the solid and
liquid forms and convert them into useful plant probiotics (Ghatnekar et al. 2009a,b).
Vermi-bio-filtration is a relatively new technology to process organically polluted water using
earthworms as biofilters (Ghatnekar and Kavian, 2000, Sinha et al. 2007; Li et. al. 2009).
Biotechnology Resource Centre (BRC) has developed a new treatment technology incorporating
the use of microorganisms, earthworms and enzymes to convert the redundant waste water
into bio- safe and bio-clean water which can be used for various secondary purposes except for
drinking. The vermi-bio-filtration-based wastewater treatment plant has been successfully
commissioned by BRC at Orient Vegetexpo Ltd., Dindori, Nashik (Ghatnekar et al. 2000) and
in gelatine manufacturing company at Gujarat (Ghatnekar et al. 2010). In fact in the last four years
this technology is implemented in many chemical industrial set ups in Vadodara, Gujarat resulting
into zero discharge of wastewater.
This paper illustrates the use of state-of-the-art vermi-bio-filtration technology to treat the
redundant wastewater from Gujarat based juice industry into bio-clean and bio-safe water.
This water is successfully used by the industry for secondary purpose like vessel and floor
washing, toilet-flushing, gardening and irrigation etc. except for human consumption.

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The scenario: Wastewater from juice making industry

The juice making industry in Gujarat produces around 12,000 litres of liquid effluent everyday.
This effluent mainly contains traces of fruit pulp, sugars and chemical preservatives used for
juice processing and also some organic solvents used for the washing the vessels after juice
production. Due to these additives, COD of the wastewater is as high as 12,000-14,000 ppm. In
addition, the sugar content is around 1,800-2,000 ppm. The organic solvents (approximately 2%
of the wastewater) also make the situation worse for the treatment of this wastewater. Due to
this and the stringent norms put forth by Gujarat Pollution Control Board, discharge of this
wastewater was a major challenge for the company. The treatment of this enormous quantity of
wastewater was a big financial burden for the concerned industry.
The major setback in the juice industry effluent treatment is low pH values, imbalance of
nutrients and considerable fluctuation in the quantity of effluent and waste matter produced
(Austerman-Haun et. al., 1997). Ozbas et. al. (2006) tried reducing the high COD levels of raw
effluents from juice industry with the help of aerobic and anaerobic biological effluent
treatments. Similar studies were carried out by El-Kamah et. al. (2010) using batch activated
sludge (AS) system and two-stage up-flow anaerobic sponge reactors (UASRs).
BRC, India developed tailor-made treatment technology for the concerned industry with the
idea of zero-discharge of the wastewater. This treatment includes the application of vermi-biofiltration technology to convert the liquid effluent using synergistic action of the selected
microorganisms, enzymes and earthworms into bio-clean and bio-safe crystal clear water. This
water can be used for secondary purpose within the industry like cleaning, washing of plant
reactors and floor, gardening and toilet use etc. Application of this treatment technology has
not only helped the industry but protecting the environment too.

Vermi-bio-filter Treatment Technology

The vermi-bio-filtration technology involves use of synergistic activity of the selected
microorganisms, enzymes and earthworms for the degradation of toxins from the waste water
converting it into bio-clean and bio-safe crystal clear water. This technology has proved to
be the best environment -friendly and cost-effective solution for this industry.

Treatment Set up
Around 80-85 sq. m area is required to set-up this novel plant having capacity to treat 12,000
Liters of effluents every day. The four-stage vermi-bio-filter plant consists of four Sintex tanks
each of 10,000 liters capacity (Figure 1 & 2). All the four tanks are connected together. The
principle of trickling filter is used in the system. The lower most layer of each tank consists of
coarse rubble. This is followed by layer of semi-crushed bricks and double layer of gravel and
fine sand. The upper most layer consists of semi-sterilized bedding material inoculated with
selected and effective microorganisms, enzymes and earthworms. The topmost layer however,
needs to be replaced after six-eight months of operation. All four tanks have been planted with
25 seedlings of Canna. The roots of these plants absorb and degrade the pollutants by osmotic
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filtration apart from giving aesthetic and ornamental appearance to the vermi-bio-filtration
system.

Figure 1:

Vermi-bio-filter tank set up

Figure 2:

Vermi-bio-filters with buffer tank

The treatment plant is designed for perpetual operations. Every day, 12,000 liters of raw
effluent is allowed to pass through all the 4 tanks in succession. The total process completion
time is more or less instant. The discharged vermi-filtered water from fourth tank is collected in
another storage tank with the capacity of 25,000 liters. This water is crystal clear and bio-safe to
use for secondary purposes except drinking.

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Results and Discussion

The analysis of wastewater during vermi-bio-filtration treatment is given in Table 1. The filtered
water collected from fourth vermi-bio-filter tank is crystal clear with no offensive odour
whatsoever and 100% bio-safe and bio-clean to use for secondary purposes except drinking.
The pH was observed to be almost neutral (7-7.3 0.06) at the end of the treatment. The COD
of wastewater is reduced from 12000-14000 11.45 ppm to less than 200-185 12.66 ppm.
Also significant reduction was observed in the BOD of the waste water i.e., 95-80 11.05 ppm
at the end of the treatment. The total recurring cost to treat 12,000 liters effluents everyday
works out to be Rs. 50-60 ( 0.75-85) whereas, in the conventional ETP plant, the running costs
will be Rs. 5000-6000 ( 7.5-10). The capital cost of the plant is also 6-7 times less than the
conventional ETP plant. In addition the said juice making Company saves the water bills; since
the treated water is re-used and re-circulated for secondary purposes.
Table 1:

Parameters
pH
BOD (ppm)
COD (ppm)

Analysis of wastewater from juice making industry during vermi-bio-filtration

treatment
Before
treatment

Vermi-bio-filter
1

Vermi-bio-filter
2

Vermi-bio-filter
3

Vermi-bio-filter
4

5.5-6.1 0.07

6.4-6.8 0.11

6.6-6.8 0.13

7.1-7.5 0.04

7-7.3 0.06

550-475 13.23

330-290 8.78

225-160 11.48

130-110 9.85

95-80 11.05

12000-14000 11.45

7500-6000 15.22

3400-2100 14.32

1200-750 11.09

200-185 12.66

COD, chemical oxygen demand; BOD, biological oxygen demand.

Each value is average of 5 observations Standard Error of the mean, Values significant at P value < 0.0005

The growth of Canna plants was also satisfactory in I tank and progressively excellent in second,
third and fourth tanks. The biomass harvested after 6-8 months from the uppermost layer of all
the tanks was used as Probiotic biofertilizer after specific pre-treatment. The schematic
representation of vermi-bio-filtration treatment technology for zero discharge of industrial
wastewater is given in Figure 3.

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Figure 3:

Vermi-bio-filtration treatment technology for successful zero discharge of

wastewater

Synergistic action of enzymes, microorganisms and earthworms in vermi- bio-filtration

The role of different types of enzymes, microorganisms, and earthworms for effluent
treatments has been previously reported. However, their potential exploitation in effluent
degradation in the most optimal way can be attained by their synergistic action in three-tier
vermiculture biotechnology (Ghatnekar et al. 2009a,b) that was applied in the bedding material
layer of the vermi-bio-filter system used in the present study.
Kavian and Ghatnekar (1999) carried out extensive studies on cellulases from L. rubellus. Their
studies confirmed that enzymes can act on specific recalcitrant pollutants to remove them by
precipitation or transformation to other products. They can also change the characteristics
of a given effluent to render it more amenable to treatment or aid in converting effluent
material to value-added products.
Kavian and Ghatnekar (1991) also conducted studies on the bio-management of dairy effluents
using an L. rubellus culture and concluded that sludge cake could support the growth of
earthworms without processing. Kavian et al. (1996) studied the bio-management of paper
mill sludge using vermiculture biotechnology. L. rubellus were used to treat approximately 1.5
tonnes of the sludge coming out of the mill daily. The sludge was successfully converted into
biofertilizer and plant tonics.
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The studies of Hamdi et al. (1991) indicated the use of Aspergillus niger as an efficient means of
protein waste bio-conversion while working on waste-water from an olive mill. Kavian and
Ghatnekar (1998) demonstrated the utility of fungal species viz., A. flavus and A. niger in the
treatment of pharmaceutical waste. In a separate study, Ghatnekar et al. (2009c) reported biomanagement of liquid effluents discharged after secondary treatment from the gelatine
manufacturing industry using a combination of A. flavus and A. niger.
In the present study, the liquid effluents discharged in each vermi-bio-filter tank were subjected
to degradation by selected enzymes, microorganisms and earthworms in each of the tank. These
three components synergistically degraded the organic and inorganic contents of the liquid
effluents, thereby initiating a series of alternate aerobic and anaerobic microbial reactions,
causing an exponential increase in the population of selected microorganisms.

Significance of earthworms and microorganisms in vermi-bio-filtration

Organic matter degraded by the selected microorganisms was further digested by colonies of
earthworms living in bedding material. Various actinomycetes inhabiting the earthworms guts
also triggered degradation of solid contents. According to Sinha et al. (2008), earthworms
body works as a biofilter and they have been found to remove BOD by over 90%, COD by 80
90%, total dissolved solids (TDS) by 9092%, and the total suspended solids (TSS) by 9095%
from wastewater by the general mechanism of ingestion and biodegradation of organic wastes,
heavy metals, and solids from wastewater and also by their absorption through body walls.
Zhao et al. (2010) reported an intensified bacterial diversity in the vermi-filtration due to the
presence of earthworms (Eisenia foetida), especially in response to nutrients in their casts.
Earthworms and microorganisms cooperate in vermi-bio-filter to ingest and biodegrade organic
wastes and other contaminants in wastewater. This extends the food chain in normal bioprocesses and thus greatly improves sewage treatment efficiency (Li et al. 2009).
Earthworms increase the hydraulic conductivity and natural aeration by granulating clay
particles (Ghatnekar et al. 2000). They also grind silt and sand particles, increasing the total
specific surface area, which enhances the ability to adsorb organic and inorganic matter from
wastewater. Intensification of soil processes and aeration by earthworms enable the
stabilization of soil and the filtration system to become effective and smaller in size (Ghatnekar
et al. 1995; Sinha et al. 2008).
Zhao et al. (2010) observed that the presence of earthworms in vermi-filter led to significant
stabilization of sludge by enhancing the reduction of volatile suspended solids. Specifically,
earthworms in the vermi-bio-filter were capable of transforming insoluble organic materials to a
soluble form and then selectively digesting the sludge particles to a finer state, which facilitated
further degradation of organic materials by the microorganisms in the reactor.

Applications of vermi-bio-filter technology

The growth of Canna plants in the first tank was mere satisfactory because of the heavy
load of pollutants. However, progressively the growth started improving from the
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satisfactory to the excellent state in the successive vermi-bio-filters. The crystal clear
water from the fourth tank was suitable for plant-vessels, floor washings and toilet flushing and
gardening.
Since the 1990s, studies on vermi-filtration technology from small to pilot scales have been
conducted. Almost all of the earlier experimental vermi-filtration processes showed a perfect
efficacy on sewage treatment, with high removal rates of COD, BOD and TSS, as well as
some ability to remove N and P (Sinha et al. 2008). Some researchers further developed vermifiltration to treat municipal sewage with relatively low organic loads (Bouch and Soto 2004;
Xing et al. 2005; Sinha et al. 2008).
Ghatnekar et al. (2000) reported the use of a vermi-filtration system for treatment of waste
water from a vegetable dehydration unit at a rate of 100 million m 3 per day. The treated pure
water was then used for irrigation of vegetable plots where onion (Allium cepa), cabbage
(Brassica oleracea) and chilli (Capsicum annum) were cultivated. Ghatnekar and Kavian (2000)
suggested the utilization of a Vermi-filtration Bio-treatment Plant to treat wastewater from a
sewage plant of a small town for irrigating agriculture. Ghatnekar et. al. (2010) were able to
evaluate the efficacy of the vermi-bio-filtration system for the treatment of secondary liquid
effluents from the gelatine manufacturing industry.
The organic content in selected liquid effluents has the expected degradation potential and is
harmless to the selected earthworm population in the upper most vermi-cast layer. The
vermi-compost obtained in the process may find use as plant probiotics and soil conditioners.

Conclusion
The vermi-bio-filtration technology used in the present study has provided the cost effective
and eco-friendly solution to the concerned juice industry. The treated water is re-circulated and
re-used for various purposes and the zero discharge is achieved. All in all, this state-of-the-art
technology has the potential to cope with industrial wastewater management and universal
water crisis concurrently.

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